steering Hyundai Terracan 2006 Repair Manual

2
DRIVING YOUR HYUNDAI
25
YC170C1-E Anti-freeze/Corrosion inhibitor The cooling system must always con- tain an Ethylene-Glycol based anti-freeze solution. The system is filled during manufacture with solution of the correct strength which should bechecked before the onset of winter and adjusted or changed as required. NOTE: The anti-freeze solution contains a corrosion inhibitor to prevent deg- radation of the aluminium castingscontained within the engine. There- fore, never, drain the system and refill with water only. In addition, anti-freeze solution must ALWAYS be used in vehicles fittedwith air conditioning, to prevent the heater matrix from freezing and sub- sequently bursting with the refrigera-tion system in use. ZC170D2-E Door Locks Should the door lock mechanism be- come frozen, a proprietary lock de-icershould be used. Never attempt to thaw a frozen door lock using hot water, since the waterwill eventually freeze and compound the problem.
o When driving in extreme condi-
tions, the windscreen wiperblades may fail to clear the screen properly due to the formation ofice upon the blade edge. It will therefore be necessary to peri- odically remove such ice to re-store their efficiency.
o If the power operated door mir-
rors become frozen, attempts toadjust these may damage the mechanism.
o The formation of snow or ice build
up inside the wheel arches mayinterfere with the roadwheels or steering mechanism. In such in-stances, unusual noises or an in- crease in steering effort may re- sult. Therefore, ensure that thewheelarches are checked peri- odically and any accumulated snow or ice removed.
o It is advisable to carry emergency equipment including, torch,shovel, tow rope, blankets etc., ifa journey is to be undertaken into areas of severe road condi- tions.
ZC170E1-E Windscreen Washers & Wipers The windscreen washer bottle should be filled with a solution of water and aproprietary winter screen wash addi- tive. The windscreen wipers should not be used if the blades are frozen tothe windscreen or if they are covered with snow, before this is removed. NOTE: Never allow undiluted screen washer fluid additive to spill upon the paintwork or use engine cool- ant anti-freeze since damage to thepaintwork may result.

3 IN CASE OF EMERGENCY
14
D060J02O-EAT AFTER CHANGING WHEELS If you have a tyre gauge, remove the valve cap and check the air pressure.If the pressure is lower than recom- mended, drive slowly to the nearest service station and inflate to the cor-rect pressure. If it is too high, adjust it until it is correct. Always reinstall the valve cap after checking or adjustingtyre pressure. If the cap is not re- placed, air may leak from the tyre. If you lose a valve cap, buy another andinstall it as soon as possible. After you have changed wheels, al- ways secure the flat tyre in its placeand return the jack and tools to their proper storage locations.
HHP5019
IF YOUR VEHICLE MUST BE TOWED
D080A02HR-GAT If your vehicle has to be towed, it should be done by your Hyundai authorisedrepairer or a commercial tow truck ser- vice. This will help assure that your vehicle is not damaged in towing. Also,professionals are generally aware of local laws governing towing. In any case, rather than risk damage to yourcar, it is suggested that you show this information to the tow truck operator. Be sure that a safety chain system isused and that all local laws are ob- served. It is recommended that your vehicle betowed with a wheel lift and dollies or flatbed equipment with all the wheels off the ground.
! CAUTION:
o Your vehicle can be damaged if towed incorrectly!
o Be sure the transmission is in neutral.
o When the engine will not start, be
sure the steering is unlocked by placing the key in the "ACC" posi- tion. D080C02HP-GAT Towing the 4 Wheel Drive Ve- hicle
HHP4044
When towing the 4WD vehicle, it must be towed by lifting all 4 wheels or using the towing dolly. 1)
2)
3)
dolly

3
IN CASE OF EMERGENCY
15
!
HHP4045
CAUTION:
o The 4WD vehicle should never be towed with the wheels on the ground. This can cause serious damage to the transmission or the 4WD system.
o When towing the vehicle, take care not to cause damage to the bumperor underbody of the vehicle.
o Do not tow with sling type truck as this may cause damage to thebumper or underbody of the ve-hicle. D080D03HP-EAT Emergency Towing
For emergency towing when no com- mercial yow vehicle is avaiable, attachchain or strap to one of the towing hooks under the front/rear of your car. Be very careful when attempting thisprocedure when the vehicle is on any unpaved surface to avoid damage to your vehicle.Nor should towing be attempted if the wheels, drive train, axles, steering or brakes are damaged. Before towing,be sure the transmission is in neutral and the key is in "ACC" (with the engine off) or in the "ON" position (withthe engine running). A driver must be in the towed car to steer it and operate the brakes.Front
HHP4035 HHP4036
Rear

5
VEHICLE MAINTENANCE REQUIREMENTS
5
20 24
I
R II I I
RR II I I I I I I I I I I I I I I I
R
F030C07HP-EAT R : Replace I : Inspect and, after inspection, clean, adjust, repair or replace if necessary
DESCRIPTION
GENERAL MAINTENANCE COOLING SYSTEM COOLANT COOLANT SPECIFIC GRAVITY MANUAL TRANSMISSION OIL AUTOMATIC TRANSMISSION FLUID BRAKE PIPES, HOSES, AND CONNECTIONS BRAKE FLUID CLUTCH FLUID
REAR BRAKE LININGS, CYLINDERS AND PARKING BRAKE BRAKE PADS, CALIPERS AND ROTORS SUSPENSION AND STEERING SYSTEM FRONT SUSPENSION BALL JOINTS
STEERING GEAR BOX, LINKAGE AND BOOTS, LOWER ARM BALL JOINT, UPPER ARM BALL JOINT
DRIVE SHAFT AND BOOTS TRANSFER CASE OIL AXLE GEAR OIL CLEAN PROPELLER SHAFT/RETIGHTEN BOLTS REAR WHEEL BEARINGS TYRE CONDITION AND PRESSURE (incl. Spare) LUBRICATE LOCKS AND HINGES CHECK ALL ELECTRICAL SYSTEMS ROAD TEST CHECK ALL SYSTEMS WITH HI-SCAN CHECK EMISSIONS CHECK 4 WHEEL ALIGNMENT CLIMATE CONTROL AIR FILTER (FOR EVAPORATOR AND BLOWER UNIT)
NO.
1
2 3 4 5 6 7 8 9
1011 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
60 72
I
RR II
R
I
RR II I I I I I I I I I I I I I I I
R
50 60
I I I I I I I I I I I I I I I I I I I I I I I
R
40 48
I
R II I I
RR II I I I I I
R I I I I I I I I I
R
30
36
I
R
I I I I I I I I I I I I I I I I I I I I I I
R
10 12
I I I I I I I I I I I I I
R I I I I I I I I I
R
MILES X 1000MONTHS
Petrol Engine Diesel Engine

5VEHICLE MAINTENANCE REQUIREMENTS
6
R R RRII II
R RR I
R
ENGINE OIL AND FILTER AIR CLEANER FILTER SPARK PLUGS (FOR PETROL ENGINE) TIMING BELTBRAKE PADS, CALIPERS AND ROTORSREAR BRAKE LININGS, CYLINDERS AND PARKING BRAKESTEERING GEAR BOX, LINKAGE AND BOOTS/LOWER ARM BALL JOINT, UPPER ARM BALL JOINT DRIVE SHAFTS AND BOOTS MANUAL TRANSMISSION OILAUTOMATIC TRANSMISSION FLUIDTRANSFER CASE OIL *1AXLE GEAR OIL *1
CLIMATE CONTROL AIR FILTER
(FOR EVAPORATOR AND BLOWER UNIT)MAINTENANCE UNDER SEVERE USAGE CONDITIONS
A, B, C, D, E, F, G, H, I, K A, B, F, G, H, I, JC, EG, H, I, JD, E, F, GC, D, E, G, H, I C, D, E, G, H, I C, D, E, F C, D, E, F A, C, D, E, F, G, H, I, JA, C, E, F, G, H, IC, E, G, H, IC, E, G, H, I C, E
F040A07HP-EAT The following items must be serviced more frequently on cars normally used under severe driving conditions. Refer to the chart below for the appropriate maintenance intervals. R : Replace I : Inspect and, after inspection, clean, adjust, repair or replace if necessary
EVERY 4,500 MILES OR 6 MONTHS MORE FREQUENTLY MORE FREQUENTLYEVERY 37,000 MILES OR 48 MONTHSMORE FREQUENTLYMORE FREQUENTLY MORE FREQUENTLYEVERY 9,000 MILES OR 12 MONTHS EVERY 60,000 MILESEVERY 27,000 MILESEVERY 60,000 MILESMORE FREQUENTLYMORE FREQUENTLY
DRIVING
CONDITION
MAINTENANCE INTERVALS
MAINTENANCE
OPERATION
MAINTENANCE ITEM
*1. Transfer Case Oil and Axle Gear Oil should be checked(and replaced if necessary) anytime they have been submerged in water over 15.7 in. (40 cm) deep.
PETROL ENGINE DIESEL ENGINE
SEVERE DRIVING CONDITIONS A - Repeatedly driving short distance of less than 5miles(8km) in normal temperature or less than 10miles(16km) in freezing temperature
B - Extensive engine idling or low speed driving for long distances
C - Driving on rough, dusty, muddy, unpaved, graveled or salt- spread roads
D - Driving in areas using salt or other corrosive materials or in very cold weather E - Driving in sandy areas
F - Driving in heavy traffic area over 90°F(32°C) G - Driving on uphill, downhill, or mountain roadH - Towing a Trailer, or using a camper, or roof rack
I - Driving as a patrol car, taxi, other commercial use or vehicle towing
J - Driving over 100 MPH(170 Km/h)K - Frequently driving in stop-and-go conditions

5VEHICLE MAINTENANCE REQUIREMENTS
10
F070J01A-AAT
o Brake pads, calipers and rotors
Check the pads for excessive wear, discs for run out and wear, and cali- pers for fluid leakage. F070K01A-EAT o Exhaust pipe and sliencer Visually inspect the exhaust pipes, sliencer and hangers for cracks, dete- rioration, or damage. Start the engineand listen carefully for any exhaust gas leakage. Tighten connections or replace parts as necessary. F070L01A-AAT
o Suspension mounting bolts
Check the suspension connections for
looseness or damage. Retighten to the specified torque.
F070M01B-AAT
o Steering gear box, linkage & boots/lower arm ball joint, upper arm ball joint
With the vehicle stopped and engine
off, check for excessive free-play in the steering wheel. Check the linkage for bends or dam-
age. Check the dust boots and ball joints for deterioration, cracks, or dam- age. Replace any damaged parts. F070N01A-AAT
o Power steering pump, belt and hoses
Check the power steering pump and
hoses for leakage and damage. Re- place any damaged or leaking parts immediately. Inspect the power steer-ing belt for evidence of cuts, cracks, excessive wear, oil contamination and proper tension. Replace or adjust it ifnecessary.
F070P01HP-AAT
o Drive shafts and boots
Check the drive shafts, boots and
clamps for cracks, deterioration, ordamage. Replace any damaged partsand, if necessary, repack the grease.
F070Q01A-AAT
o Air conditioning refrigerant
Check the air conditioning lines and
connections for leakage and damage. Check air conditioning performance ac- cording to the relevant shop manual ifnecessary.

Engine Compartment ................................................... 6-2
Daily Operating Checks ............................................... 6-4
Engine Oil ..................................................................... 6-4
Engine Oil and Filter Replacement .............................. 6-8
Engine Coolant Checking and Replacing .................... 6-9
Changing the Air Cleaner Filter ...................................6-12
Manual Transmission Lubricant ..................................6-15
Automatic Transmission Lubricant ..............................6-16
Brake System Checking ............................................. 6-18
Checking the Clutch Fluid ........................................... 6-19
Air Conditioning System Maintenance ........................ 6-20
Changing the Climate Control Air Filter .. ....................6-22
Checking Engine Drive Belts ...................................... 6-24
Fusible Links ............................................................... 6-25
Battery Mai ntenance ................................................... 6-27
Checking Electric Cooling Fans .................................6-29
Power Steering Fluid Level ......................................... 6-29
Fuel Filter ..................................................................... 6-30
Replacing Headlight Bulbs .......................................... 6-31
Headlight Aiming Adjustment ...................................... 6-33
Bulb Wattages ............................................................. 6-35
Fuse Panel D escription ............................................... 6-36
OWNER MAINTENANCE
6
6

6 OWNER MAINTENANCE
2
1. Power steering fluid reservoir 2. Brake fluid reservoir 3. Engine cover 4. Battery 5. Fuse and relay box 6. Windscreen washer fluid reservoir
7. Air cleaner filter
8. Radiator cap
9. Engine oil filler cap
10. Automatic transmission fluid level
dipstick (Vehicle with automatictransmission)
11. Engine oil level dipstick
12. Coolant reservoir cap
G010A01HP-EAT Petrol Engine Compartment (3.5 V6)
CAUTION:
When inspecting or servic-
ing the engine, you should handle tools and other heavy objects carefully so that the plastic cover of theengine is not damaged.
!
ENGINE COMPARTMENT
G010A01HP-E

6
OWNER MAINTENANCE
3
G010C01HP-EAT
Diesel Engine Compartment (2.9 CRDi)
1. Brake fluid reservoir
2. Clutch fluid reservoir (Not all models)
3. Engine oil level dipstick
4. Engine cover 5. Engine oil filler cap
6. Battery
7. Fuse and relay box
8. Windscreen washer fluid reservoir
9. Air cleaner filter10. Radiator cap
11. Fuel filter
12. Power steering fluid reservoir
13. Coolant reservoir capCAUTION:
When inspecting or servic-ing the engine, you shouldhandle tools and other heavy objects carefully so that the plastic cover of theengine is not damaged.
!
G010C01HP-E

6 OWNER MAINTENANCE
4DAILY OPERATING CHECKS
SG020B1-E The following items should be checked on a daily basis or whenever the vehicle is refuelled, whichever occurssooner.
o Engine oil level.
o Coolant level.
o Power steering fluid level.
o Brake fluid level.
o Windscreen washer fluid level.
o Battery condition.
o Tyre condition and pressures.
o Operation and cleanliness of all lighting equipment.
o Windscreen wiper and washer op-
eration.
o Horn operation.
o Warning light operation.
o Adjustment and cleanliness of mir- rors.
o Seat and seat belt adjustment and operation.
o Fluid leakage. The vehicle must not be driven if the daily operating checks indicate that any item of equipment related to the safety or roadworthiness of the ve-hicle is not functioning correctly.ENGINE OIL
G030A01FC-EAT The correct engine oil level is of para-
mount importance. An excessively high or low oil level may result inirreparable damage being sustained by the engine. The engine oil level must be checked on a daily basis,whenever the vehicle is refuelled or before starting a long trip, whichever occurs sooner.
In addition, it is imperative that only
an approved grade and specificationof oil is used to avoid the possibility ofserious engine damage and prema- ture wear. The use of "budget price" oil is a false economy that must beavoided if the maximum reliability and useful life is to be obtained from the vehicle.MAINTENANCE PRECAU- TIONS
G020D01TG-EAT Improper or incomplete service may
result in problems. This section gives instructions only for the maintenanceitems that are easy to perform.
Several procedures should be done by
Hyundai authorised repairer.
NOTE: Improper owner maintenance dur-
ing the warranty period may affect warranty coverage.